EMERGENCY SERVICE GUIDE

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Harold Stafford
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2 HMSA EMERGENCY The purpose of this manual is to provide basic knowledge and understanding of the 300 Series Hybrid vehicle high voltage system For the assistance of SPECIAL EMERGENCY PERSONNEL in the rescue of Hino 300 Series motor vehicles. Rights for alteration to data and specification, at any time, are reserved. Any such alteration will be advised by the Product Support Division via Bulletins It is important to note, that the following information contained in this document is correct to our best knowledge, however errors may have occurred in its transcription. HMSA will not accept any liability for such errors. This document is only intended as a guide. Special Emergency Service Personnel must also refer to Hino Workshop Service Manuals, where applicable. Hino Motor Sales Australia 6-10 Parraweena Road, Taren Point, NSW 2224 Sydney 2008 Publication # HMSA/EMERGENCY300HYBRID/0908 Version 1.2

3 HMSA EMERGENCY It is imperative that SPECIAL EMERGENCY personnel read and follow the correct safety guidelines, instructions and procedures contained herein before attempting to rescue the 300 Series Hybrid vehicle. The 300 Series hybrid vehicle utilises a high voltage system (300 Volts) to assist the Diesel engine as a mean of propulsion. In the event rescue personnel fail to follow the correct safety guidelines, precaution and instructions provided herein, have a greater risk of receiving an electrical shock, personal injury or even death. It is also important to note, that, the 300 Series Hybrid vehicle can only be serviced or repaired by trained personnel. Other parties involved in the service, repair or mounting body to this vehicle MUST have had an induction training prior to commencement of work. HMSA will not accept any liability for failing to follow the correct safety guidelines, instructions and procedures. Hino Motor Sales Australia 6-10 Parraweena Road, Taren Point, NSW 2224 Sydney 2008 Publication # HMSA/EMERGENCY300HYBRID/0908 Version 1.2

4 CONTENTS 1) 300 SERIES HYBRID BROCHURE 2) EMERGENCY LINES..Pg 01 3) 24 VOLT CIRCUIT Pg 12 4) 300 VOLT CIRCUIT...Pg 20 5) HYBRID BATTERY Pg 29 6) LEAD-ACID BATTERY.Pg 36 7) SUPPLEMENTARY RESTRAINT SYSTEM...Pg 38 8) HYBRID VEHICLE RECOVERY...Pg 49

6 ISOLATION OF HYBRID BATTERY

7 EMERGENCY RESPONSE LINES EMERGENCY RESPONSE LINES On arrival, emergency personnel should follow their standard operating procedure to assist the vehicle involved in the accident. Emergency procedures involving the 300 Series vehicle Hybrid may be handled like other light duty trucks, however additional notes may assist the special service services personnel while dealing with Hino Hybrid vehicles. Warning! Never assume the 300 Series Hybrid vehicle electrical power is completely OFF because the vehicle is silent. Always observe Always observe the combination meter warning lights status to verify whether the ignition switch is set to the ON position. Immobilizing Vehicle Chock the vehicle s wheel and apply the parking brake. 1

8 EMERGENCY RESPONSE LINES EMERGENCY RESPONSE LINES CONT D Disabling the 24 Volt Vehicle System Performing any of the two procedures below will disable the vehicle 24 Volt system. 1) Disconnecting the (-) negative battery terminal, followed by disconnecting the (+) positive battery terminal to interrupt power supply to the vehicle electrical system. 2) With caution, snip the (-) negative battery terminal and then snip the (+) positive battery terminal avoiding contacting the metal chassis of the vehicle to avoid electrical sparks and cause a fire. (+) (-) 2

9 EMERGENCY RESPONSE LINES EMERGENCY RESPONSE LINES CONT D Disabling the 300 Volt Hybrid System Performing procedure (2) only will disable Hybrid system. 1) In the event the Safety Plug can not be reached, disconnect the (-) negative battery terminal, followed by disconnecting the (+) positive battery terminal to interrupt power supply to the vehicle electrical system and Hybrid system. 2) When removing the Control Power Unit Safety Plug, allow 5 minutes for the system capacitor to discharge. After this time period, the vehicle can then be rescued. REFER PAGE 5 3

10 EMERGENCY RESPONSE LINES It is imperative that the Hybrid Battery be isolated before any type of work is commenced with the Hybrid vehicle (e.g. Vehicle servicing, removal of manual transmission, clutch replacement, repair to the Hybrid Control Power P Unit or any other work while the vehicle is being serviced / repaired at the Dealership). It is also important to note that the Dutro Hybrid vehicle must be serviced only by authorised Hino Dealerships and authorised trained service personnel. The failure to follow this guidelines may result in damage to the e vehicle and personal injures, resulting in death! 4

11 EMERGENCY RESPONSE LINES DO NOT USE IF 5

12 EMERGENCY RESPONSE LINES 6 x 10 mm Hexagon Head 6

13 EMERGENCY RESPONSE LINES SLIDE TO THE RIGHT 7

14 EMERGENCY RESPONSE LINES 150 A Fuse 8

15 EMERGENCY RESPONSE LINES 9

16 EMERGENCY RESPONSE LINES SLIDE TO THE LEFT 10

17 EMERGENCY RESPONSE LINES 11

18 24 VOLT CIRCUIT

19 24 VOLT ELECTRICAL SYSTEM 24 VOLT SYSTEM Hybrid Vehicle (HV) 24 Volt System Wear Protective safety clothing at all times! The 24 Volt system in the 300 Series vehicles is independent of the 300 Volt system. Although there are a number of components in the Hybrid Control Power Unit that is operated by a 24 / 12 Volt power supply, the Hybrid Control Power Unit must be treated as a high voltage system. 24 Volt Electrical Circuit The electrical wiring diagrams included in this section relates to systems that operate with 24 / 12 Volt power supply. A Red Tick next to the electrical circuit description identifies circuits that can be cut through with Jaws of Life 12

20 24 VOLT ELECTRICAL CIRCUIT 24 VOLT EQUIPMENT 13

21 24 VOLT ELECTRICAL CIRCUIT JAWS OF LIFE CAN BE USED ON THIS CIRCUITS 24 VOLT CIRCUIT 14

22 24 VOLT ELECTRICAL CIRCUIT JAWS OF LIFE CAN BE USED ON THIS CIRCUITS 24 VOLT CIRCUITS 15

23 24 VOLT ELECTRICAL CIRCUIT JAWS OF LIFE CAN BE USED ON THIS CIRCUITS 24 VOLT CIRCUIT 16

24 24 VOLT ELECTRICAL CIRCUIT JAWS OF LIFE CAN BE USED ON THIS CIRCUITS 17

25 24 VOLT ELECTRICAL CIRCUIT JAWS OF LIFE CAN BE USED ON THIS CIRCUITS 24 VOLT CIRCUIT 18

26 24 VOLT ELECTRICAL CIRCUIT JAWS OF LIFE CAN BE USED ON THIS CIRCUITS 19

27 300 VOLT CIRCUIT X

28 300 VOLT HYBRID SYSTEM 300 VOLT HYBRID SYSTEM Hybrid Vehicle (HV) 300 Volt System Wear Protective safety clothing at all times! The 300 Volt system in the 300 Series vehicles is independent of the 24 Volt system. Although there are a number of components in the Hybrid Control Power Unit that is operated by a 24 / 12 Volt power supply, the Hybrid Control Power Unit must be treated as a high voltage system. 300 Volt Electrical Circuit The electrical wiring diagrams included in this section relates to systems that operate with HIGH VOLTAGE 300 VOLT POWER SUPPLY. A Cross placed on top of the Jaws of Life and also next to the electrical circuit description indicate electrical circuits that can NOT be cut through with Jaws of Life X 20

29 HYBRID SYNERGY DRIVE COMPONENTS Jaws of life CAN NOT be used Synchronous Electric Motor Clutch Transmission Diesel Engine U V W Nickel Metal Hydride Battery 300 Volts Inverter HV ECU DC ~ AC CPU (Control Power Unit) 21

30 HYBRID SYNERGY DRIVE COMPONENTS X 22

31 HYBRID SYNERGY DRIVE COMPONENTS 23

32 HYBRID SYNERGY DRIVE COMPONENTS Jaws of life CAN NOT be used 300 VOLTS SYSTEM X 24 VOLTS SYSTEM 300 VOLTS SYSTEM 24

33 HYBRID SYNERGY DRIVE COMPONENTS Jaws of life CAN NOT be used X 300 Volts 300 Volts 24 Volts Nickel Metal Hydride Battery Inverter Assembly HV ECU 25

34 HYBRID SYNERGY DRIVE COMPONENTS Jaws of life CAN NOT be used X 300 VOLTS X 300 VOLTS CONTROL POWER UNIT 26

35 HYBRID SYNERGY DRIVE COMPONENTS Jaws of life CAN NOT be used X X 27

36 HYBRID SYNERGY DRIVE COMPONENTS Jaws of life CAN NOT be used X X X 28

HYBRID VEHICLE BATTERY

HYBRID BATTERY X HYBRID BATTERY NICKEL METAL HYDRIDE HYBRID VEHICLE BATTERY Hybrid Vehicle (HV) Battery Pack. Wear Protective safety clothing at all times! The 300 Series Hybrid contains a high voltage